Cylinder Head Assembly: Service and Repair

1. Relieve fuel system pressure.
2. Disconnect battery ground cable and drain cooling system.
3. Remove air intake tube from throttle body.
4. Remove spark plug wires and retainers.
5. Remove air intake tube from air cleaner.
6. Disconnect cooling hose from thermostat cover.
7. Disconnect vacuum hoses and cooling hoses from throttle body and intake manifold.
8. Disconnect throttle cable.
9. Disconnect fuel lines at fuel filter and pressure regulator.
10. Disconnect main harness connector.
11. Disconnect Exhaust Gas Oxygen (EGO) sensor connector and remove ground.
12. Disconnect intercooler tubes from turbocharger.
13. Disconnect ground wire and straps from cylinder head.
14. Remove timing belt covers and timing belt.
15. Remove exhaust manifold and turbocharger assembly.
16. Remove intake manifold support upper bolts.
17. Remove cylinder head cover.
18. Remove cylinder head and intake manifold as an assembly.
19. Reverse procedure to install, noting the following:
a. Ensure coolant passage opening in intake manifold gasket align with manifold and cylinder head.

Fig. 5 Cylinder Head Bolt Tightening Sequence:

b. Tighten cylinder head bolts in sequence in two steps: first, Torque bolts to 15-25 ft lb, then repeat sequence and torque bolts to 56-59 ft lb.